Marmox Thermoblocks Insulate Tudor Reconstruction

The reconstruction of a rambling old farmyard close to Ely in East Cambridgeshire is making use of well proven Marmox Thermoblocks, specified in three widths as the ideal solution for tackling thermal-bridging around the building perimeter as part of a well-insulated design. Mitchell’s Barn is replacing a sprawling complex of dilapidated tin cowsheds and a rather more attractive oak barn which was founded on a plinth of Tudor era bricks.

The original planning permission allowed for the reconstruction of the latter structure, but when the owner, Ben Hughes came to dismantle the outer envelope, much of the timber was found to be rotten while the bricks showed significant frost-damage. The work which got under way earlier in the autumn, is therefore seeing both 215mm and 140mm wide Thermoblocks being used to support a 800mm high brick base which will then carry the conserved oak beams, creating a traditional looking inner ambience.

Ben Hughes commented: “I have taken responsibility for the design as well as the construction of what will be a four-bedroom, three-bathroom property, as a self-build project with the help of a builder, Peter Axton who I have worked with on previous projects. As it is such an exposed site, the house takes the form of a three-sided courtyard which will shelter the south facing terrace. Primarily a Class Q conversion of an agricultural building into a residential building, the new structure is all single storey, but with a mezzanine to accommodate the plant and services that will include an air source heat pump and MVHR system."

"Essentially, we are rebuilding it at the same scale using the same traditional techniques as the original, with additional oak for the frame coming from a tree felled on the site. In order to meet Building Regulations, we have gone for an insulated cavity wall with 150m of PIR insulation for the floor and roof, but when I was researching how to address the issue of thermal bridging at the floor wall junction, Marmox Thermoblock seemed to be the only targeted product solution. In terms of the loadings and the insulation values I am certain it will work well. It’s a good mix of old and new technologies and I’m very happy with the design overall.”

In total Ben and his bricklayer have used 144 x 140x65mm blocks plus 18 x 100x65mm blocks and 50 x 215x65mm blocks, purchased from Insulation Shop on-line. Bedded in conventional mortar, the stepped overlaps between adjacent Thermoblocks have been secured using a high performance (Sika) adhesive.

Ben concluded saying: “The work is progressing well and my bricklayer, Danny, has had no issues with laying the Thermoblocks or cutting them where it has been necessary. Some of the packages, such as for the windows, are still to be placed, but I am confident of the finished property exceeding the current Building Regulation requirements and making a very comfortable home.” 

He is also consulting with Marmox’s technical department over the use of the company’s even longer established Multiboard thermal tilebacker board and other products for fitting out the bathrooms, including at least one wetroom. With a proven track record going back more than a decade, Thermoblocks are available in widths of 100, 140 and 215mm and feature a unique design where two rows of high strength epoxy concrete mini-columns are encapsulated in sections of XPS (Extruded polystyrene).

They are attached at either end to the top and bottom layers of glass-fibre reinforced polymer concrete to achieve a strong bond with the rest of the structure. As well as being used in basement construction and around the floor-wall junction – supporting timber frame as well as masonry walls – Thermoblocks regularly feature at first floor level and beneath parapet walls. They are further employed for swimming pool construction. www.marmox.co.uk

Kashdan-Brown Architects Reaches For The Sky With SterlingOSB Zero

As the annual SterlingOSB Zero/RIBAJ competition celebrated its 10th anniversary,  the 2025 competition entitled Powers of Ten, challenged architects to explore the principles of scale. Entrants were unrestricted by building standards and were free to play with the concept of scale and design a structure from competition sponsor West Fraser's SterlingOSB  Zero.

This year's competition winner, Kashdan-Brown Architects, imagined a 1:10 scale model reconstruction of the 140-metre-high missing spire of Malmesbury Abbey in Wiltshire. Here Julian Kashdan-Brown talks about his winning entry and what SterlingOSB Zero provides architects. 

Q. What inspired your design for the competition? 

The brief this year was very much about scale, and scale is an interesting thing looking back into the past at some enormous edifices. Of course, with the economy with which we must build today, it's impossible to build to the kind of scale common previously. I was interested in trying to produce a piece at a small scale; but which 

evoked the idea of the grand scale of buildings of the past. That’s what eventually inspired the idea to recreate the fallen part of Malmesbury Abbey which is, of course, ten times the size of the OSB version that we designed ourselves. 

Q. What are some of the common challenges you face in meeting sustainability targets? 

It is increasingly difficult to meet sustainability targets today.  To begin with, it was about the nature of the material that you were specifying and how that material might be produced; and how much energy is consumed in doing that. Now it's about whole life cycle costings as well.  It is, therefore, important to consider every aspect of the material. In the case of SterlingOSB Zero, it's not just the timber that is within; it’s the way in which it is bonded together; and the sources from which those come and the degree of transportation involved. We need to consider all these points now when we specify materials for buildings. 

Q. How has designing with SterlingOSB Zero informed your view as a material regarding its versatility and aesthetic? 

With SterlingOSB Zero, I probably have more experience of it than many architects might have as I teach architecture and engineering students at the University of Bath. One or two of the projects, particularly the first project they are involved in, is often centred around building something with a certain number of materials. One of these is OSB.

I have seen these group projects come to fruition over the last decade and I've seen many students master the workability of OSB and the ways in which they might be able to join the board with other materials as well. I think that's informed my understanding of the degree of accuracy that you can achieve with the material and the way it's cut, and the way it's bonded to other materials as well.  It’s been particularly helpful for me.  

For further information, call 01786 812 921 or visit https://uk.westfraser.com

Firefly® Phoenix Continues To Protect Home Bargains Chain

As value for money makes the Home Bargains brand an increasingly popular choice with price conscious shoppers, the national retailer is continuing to increase its coverage by building new stores in locations such as Camborne in Cornwall, with products from the FIREFLY® range repeatedly being included in the specification to help ensure the safety of staff and customers.  As with many of its outlets, the existing 9,150sq ft warehouse and sales floor on the Camborne Retail Park is being refurbished by Oakhurst (Southport) Ltd. with WPL Consulting filling the role of project architect. 

The Phoenix Vertical, Collaroll and ancillary FIREFLY® products have been used to create a semi-permanent fire barrier that is suspended from the underside of the pitched, metal decked roof. Installation of the 60- minute rated fire curtain and smoke barrier was carried out by sub-contractor S R Shopfitting over a period of just a couple of days in early July, with the new Home Bargains outlet scheduled for its official opening on August 22nd. Working from hydraulic platforms, the lightweight Phoenix fire barrier was fixed to sections of steel angle bolted onto the roof members, with all overlaps sealed using FIREFLY® High Temperature Adhesive, while butt joints were fixed using stainless steel staples. 

While the Collaroll was used to wrap the high-level steel beams, the manufacturer’s ablative batts – introduced into the range last year to assist with tasks like creating protected zones – fill voids beneath the soffit level. The Site Manager for Oakhurst, Kerry Humphrey’s, commented: “Along with a number of S R Shopfitting’s operatives, I have been on the FIREFLY® training course at its Rochdale premises and consider the systems to be far easier to install than the previous solution, which involved installing quite bulky sections of rock mineral wool which, even for those not directly involved with the work, tended to make you itch quite badly.  The Phoenix and other products, by contrast are light to handle and easy to fix.  It’s a brilliant system.”

“In respect of the Home Bargains stores we’ve been involved on, the fire requirements vary slightly between England and Scotland, where the regulation is for a full fire and smoke barrier and we know FIREFLY® will provide any special details we need for new jobs.  With the barrier now installed by SR Shopfitting, the internal construction will continue so that the Phoenix terminates on top of the ceiling structure.  Everything is going well and we are on schedule to handover the building on the 21st.” 

Manufactured from woven and non-woven glass, the FIREFLY® range is designed to optimise resistance to flame and smoke as well as offer heat protection in a wide range of scenarios. The barriers are easy to install horizontally or vertically using a full selection of FIREFLY® ancillary products to ensure a fully tested and certified installed system.  www.tbafirefly.com